presentation of supreme project - epma

A.WITOMSKI, L.AIXALA, T. BAFFIE,

CEA-LITEN, France

PRESENTATION OF SUPREME PROJECT

EuroAM meeting, EuroPM 2017 Conference, October 2-5 2017, Milan, Italy

[email protected]

[email protected]

Sustainable and flexible powder metallurgy processes optimization by a holistic

reduction of raw material resources and energy consumption

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SUPREME CONSORTIUM

EuroAM meeting @ PM2017 | Presentation of SUPREME project | A.WITOMSKI et al.

Participant No*

Participant organisation name Participant Short Name

Country

1 Commissariat à l’Energie Atomique et aux énergies alternatives

CEA France

2 Outotec Oyj OUTOTEC Finland

3 MBN Nanomaterialia MBN Italy

4 Atomising systems Ltd. ASL United Kingdom

5 GKN Sinter Metals GKN Germany

6 Fundación Prodintec PRODINTEC Spain

7 Centre technique Industriel de la Plasturgie et des Composites

IPC France

8 TWI Ltd TWI United Kingdom

9 RHP Technology GmbH RHP Austria

10 Tecnalia Research & Innovation TECNALIA Spain

11 Renishaw PLC RENISHAW United Kingdom

12 Innovació i Recerca Industrial i Sostenible IRIS Spain

13 MBA Incorporado SL MBA Spain

14 PRISMAdd PRISMA France

15 Dellas srl DELLAS Italy

16 Centro Ricerche Fiat CRF Italy

17 European Powder Metallurgy Association EPMA Belgium

Total cost: 9.8 M€

EU contribution : 8 M€

Duration: 3 years

From 01/09/2017 to 31/08/2020

DD

5 RTO

6 SME

5 Large companies

1 Non-profit

Sustainable Process Industry through Resource and Energy Efficiency

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POWDER METALLURGY PROCESSES


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AGENDA


1. CONCEPT & METHODOLOGY

2. OBJECTIVES

3. EXPECTED IMPACTS

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SUPREME CONCEPT


• Optimize ferrous and non-ferrous metal PM processes, currently individually available at TRL7 and beyond,

by cross-sectorial improvements in material and energy efficiency throughout the supply chain, from raw

materials (fluids, solids or gases, including minerals and water) to finished products in a range of different

end-applications.

• Demonstrate a new integrated and optimized approach of a set of PM production routes in real

industrial settings, from TRL5 to TRL7, i.e. ready for adoption on the PM market.

Demonstrator

#1

Demonstrator

#2

Demonstrator

#3

Demonstrator

#4

Courtesy : GKN

Courtesy : RENISHAW

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METHODOLOGY : PRODUCTION ROUTES


Located all along the value chain (1 at each step), where KPIs will be

monitored to reach the overall SUPREME objectives

5 use cases

#1

#2

#3

#4

4 demonstrators

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AGENDA



2. OBJECTIVES

3. EXPECTED IMPACTS

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OVERALL OBJECTIVES


Two main KEY PROCESS INDICATORS (KPI) to quantify material and energy efficiency improvements:

→ Raw material resources efficiency: defined either

(i) absolutely as the amount of material consumption for a given process (typically in kg),

(ii) relatively, as the raw material yield losses compared to the current practice in the sector.

Several raw material resources will be considered, accordingly to the process requirement and the most

significant metrics that can be optimized: solids / fluids (including water) / gases.

→ Energy efficiency: defined either

(i) absolutely as the amount of energy consumption for a given process (typically in kWh),

(ii) relatively, as the rate of energy losses compared to the current practice in the sector.

Two KEY PROCESS INDICATORS derived from the above main KPIs to track impacts on productivity and

CO2 emissions:

→ Production rate: defined as productivity (typically in kg/hour).

→ Carbon dioxide emissions: defined either

(i) absolutely as the amount of carbon dioxide emitted for a given process (typically in kt),

(ii) relatively, as the rate relative reduction of CO2 emissions compared to the current practice in the

sector

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OVERALL OBJECTIVES


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SPECIFIC OBJECTIVES (SELECTION)


Objective 2: Reduction of raw material resources and energy efficiency in ferrous (316L, Tool steel, Hard Carbon steel, Fe-

based composite) and non-ferrous metal (Hastelloy® C22 and Inconel® 625) powder production processes, i.e. (i) gas

atomization; (ii) water atomization and (iii) ball milling

Objective 3: Improvement of raw material resources (316L, 17-4PH, Tool steel, Hard carbon steel, Hastelloy® C22, Inconel® 625

& 718) and energy consumption in L-PBF and DED additive manufacturing processes

Objective 5: To demonstrate at TRL 7 the global integrated PM process optimization from minerals to end parts by a validationon 5 use cases in agreement with material performances, total cost breakdown and market volumes requirements

Objective 6: To develop and implement a quality and process control based on an eco-innovation methodology in order toensure stable and flexible production routes towards a higher efficiency integrated powder metallurgy approach

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WORKPACKAGE DEDICATED TO AM


Objective : Increase the yield and the productivity of 3D manufacturing processes

(LMD = Laser Metal Deposition, PMD = Plasma Metal Deposition, and L-PBF =

Laser Powder Bed Fusion)

WP3 Tasks Objectives

Task 3.1 Increase L-PBF process efficiency

Task 3.2 Increase the productivity of LMD and PMD

Task 3.3 Demonstrate a possible increase of powder reuse with L-BPF and

LMD

Task 3.4 Energy saving by replacing gas atomized powder by water atomized

powder

Task 3.5 Optimize powder granulometry for L-PBF, LMD and PMD

Task 3.6 Improve the maturity level of Hard C steels with L-PBF

Task 3.7 Demonstrate the outcomes of WP3

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AGENDA



2. OBJECTIVES

3. EXPECTED IMPACTS

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EXPECTED IMPACTS


Commissariat à l’énergie atomique et aux énergies alternatives

17 rue des Martyrs | 38054 Grenoble Cedex

www-liten.cea.fr

Établissement public à caractère industriel et commercial | RCS Paris B 775 685 019

THANKS FOR YOUR

ATTENTION !

[email protected]

[email protected]

Project funded by the European

Union’s Horizon 2020 research and

innovation programme under grant

agreement No 768612

presentation of supreme project - epma

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